Surgical cement containing α-tricalcium phosphate, poly(carboxylic acid) and water

ABSTRACT

Here disclosed are surgical cement useful for filling defect parts and vacant part of bones and teeth which comprises (a) a component (A) of self-hardening  alpha -tricalcium phosphate powder, (b) a component (B) of a surgically acceptable water-soluble poly(carboxylic acid), and (c) water and which is prepared by mixing the component (A), (B) and water or mixing the component (A) and an aqueous solution of the component (B), then kneading the mixture.

FIELD OF THE INVENTION

The present invention relates to a surgical cement, more particularly the invention pertains a surgical cement containing α-tricalcium phosphate as the principal component and a method for preparing the same.

DESCRIPTION OF THE PRIOR ART

To date, many materials applicable to living body such as plastic materials or various kinds of metals, for example, gold, silver, alloys of palladium, Ni-Cr alloys, Co-Cr alloys, amalgam, stainless steel, titanium alloys have been proposed and they have been used in many fields such as orthopedics and dentistry. These materials have many applications for tooth crown, radicular, and further they are tried to use in artificial bones, artificial joints or the like. They have a high reliability in their mechanical strength and are capable of precision processing, while they suffer various undesirable modification such as dissolution, corrosion, deterioration due to the severe environmental conditions in living body, and are fatigued during the long-term service and accompany a foreign substance forming reaction.

Then, ceramics materials having a relatively good affinity for living tissues are recently paid great attention.

For example, there are proposed such as artificial bones, artificial joints and radiculars composed of Al₂ O₃ single crystal or sintered body thereof or those constituted by hydroxyapatite.

However, these inplant materials have disadvantages such that they are too hard and fragile, these being common to the ceramics. Many problems to be solved still remain in order to adopt them as the material for artificial bones and radiculars.

On the other hand, a cement in which orthophosphoric acid solution is conventionally used as the setting solution, in the field of surgical cement. As such cement, there are known, for instance, zinc phosphate cement obtained by kneading zinc oxide with about 70% aqueous orthophosphoric acid solution and silicate cement which is used in the form of a product kneaded silicate glass with aqueous phosphoric acid solution and the like. However, these cements are highly acidic due to the phosphoric acid used and accordingly, they have pulpal injury effect and moreover they are insufficient in the adhesion with teeth.

On the contrary, U.S. Pat. Nos. 3,655,605, 3,741,926, 3,751,391 and 3,804,794 propose zinc oxide-polycarboxylate cement in which aqueous poly(carboxylic acid) solution having a weak injury effect is used instead of the aqueous orthophosphoric acid solution.

In addition, ionomer cements are developed in order to modify the compressive strength of cements and in said ionomer cements, fluoroaluminosilicate is used in place of zinc oxide, which is set with an aqueous solution of poly(carboxylic acid) (see, for instance, U.S. Pat. Nos. 3,814,717, 4,016,124, 4,089,830 and British Pat. No. 1,316,129). However, the ingredients used in these cements chemically differ from those of the teeth and bones and therefore, many problems to be overcome still remain, such that these are less compatible to living tissues, that they irritate pulpal tissues and that they penetrate into dentinal tubule and the like.

Moreover, in order to adjust the setting speed of carboxylate cements composed of zinc oxide and poly(carboxylic acid), there are proposed such as a composition which is prepared from the carboxylate cement by adding, as a filler, a small amount of calcium phosphate powder thereto (see, U.S. Pat. Nos. 3,655,605, 3,751,391 and 4,288,355) and a cement composition obtained by mixing hydroxyapatite as principal component with an inorganic powder such as ZnO, CaO, Al₂ O₃, Ca₃ (PO₄)₂, SiO₂ and poly(carboxylic acid) (see, for example, Japanese Patent Laid-Open Appln. No. 83605/1983).

Furthermore, Japanese Patent Laid-Open Appln. No. 182263/1984, which was issued after the application of this invention, discloses a method for preparing a surgical cement which comprises mixing α-tricalcium phosphate with an inorganic acid or an organic acid such as nitric acid, hydrochloric acid, phosphoric acid, formic acid, acetic acid, lactic acid and the like.

However, such surgical cements do not satisfy the requirements for compatibility to living tissues and for compressive strength at the same time.

The materials applied to living body are always in contact with the living tissues and are subjected to long-term service. Therefore, they must be safe, that is to say, they must not have harmful effects on the living body such as tumorigenesis and also they do not irritate the tissues around the part where the cement is filled or applied. In addition, they should have a good compatibility to the living cells i.e., a good adhesion to them and a self-ossification, in other words, the assimilation between neonatal bones and the surface of the material.

Under these circumstances, there has been a strong need for the development of materials for living organisms which include components similar to principal components of the teeth or bones and have an excellent compressive strength.

DETAILED DESCRIPTION OF THE INVENTION

The principal object of this invention is to provide surgical cements applicable in the fields of medicine and dentistry, which have components quite similar to those of the teeth or bones of the living organisms, so that they do not cause a foreign substance-formation reaction and they are quite excellent in their compatibility to the living organism.

Another object of this invention is to provide a surgical cement which can be filled into root canals of teeth or defects and vacant parts formed due to diseases or external factors.

A further object of this invention is to provide a surgical cement applicable as a restorative material to repair the alveolar bone disappeared by degeneration and as a filler for tooth and bone fissure which are formed due to external factors such as periodontosis and traffic accidents.

A further object of this invention is to provide a surgical cement of a high compressive strength, which is also applicable to the case where a high strength is required immediately after filling.

A further object of this invention is to provide a surgical cement, thereby the structure and functions of the injured parts and vacant parts (cavity) being repairable or restorable.

Aforementioned object and other object of the invention may be accomplished by the following surgical cement.

The surgical cement according to the present invention, comprises self-hardening α-tricalcium phosphate, a surgically acceptable water-soluble poly(carboxylic acid) and water.

In the self-hardening α-tricalcium phosphate used in the surgical cement of this invention, the term "self-hardening" means that the phosphate reacts with surgically acceptable water-soluble poly(carboxylic acid) disclosed below in more detail, to set together.

In order to attain the objects of this invention, self-hardening α-tricalcium phosphate [α-Ca₃ (PO₄)₂ ] powder must be used.

In general, said α-tricalcium phosphate may be prepared according to one of the following methods. For example, one method comprises heating the dried calcium hydrogen phosphate dihydrate [CaHPO₄.2H₂ O], at a temperature of from about 300° to 500° C. to form γ-calcium pyrophosphate (γ-Ca₂ P₂ O₇), then uniformly mixing the equimolar amount of γ-calcium pyrophosphate and calcium carbonate, calcining the mixture, after sufficiently drying, at a temperature of from 1,000° to 1,300° C., preferably around 1,200° C., for about one hour and finely pulverizing the calcined product to obtain powder having a size of equal to or less than 100 μm. Another method for preparing α-tricalcium phosphate [α-Ca₃ (PO₄)₂ ] powder comprises uniformly mixing calcium hydrogen phosphate dihydrate and calcium carbonate at a molar ratio of 2:1, then calcining the mixture under the same conditions as disclosed above and pulverizing the calcined product according to aforementioned manner.

The α-tricalcium phosphate powder thus obtained may be further processed according to the following procedures which comprise compressing the α-tricalcium phosphate powder, calcining the pressed powder at a temperature of from 1,200° to 1,500° C., preferably 1,200° to 1,300° C. for at least one hour and then, pulverizing the calcined product as in the case mentioned above to form fine powder having a size distribution of 0.5 to 20 μm.

In addition, α-tricalcium phosphate may be prepared by compressing amorphous tricalcium phosphate under press and calcining and pulverizing according to the same procedure as before.

In the latter method in which the calcination and the pulverization treatments are carried out twice, the first treatment is effected to form α-tricalcium phosphate and the second treatment is carried out to improve density of the powder and to enhance the compressive strength. However, the product obtained by the first treatment may surely be applicable to the surgical cement as the principal component thereof and provides satisfactory results.

Furthermore, if desired, there may be added to the cement 0.1 to 10% by weight, preferably 0.1 to 2% by weight of aluminum phosphate before the first or the second calcination and pulverization steps, in order to improve the compressive strength of the final surgical cement, more or less.

In addition, another essential component other than α-tricalcium phosphate is surgically acceptable water-soluble poly(carboxylic acid). All the known poly(carboxylic acid) conventionally used in the surgical cement such as cement containing zinc oxide as principal component or ionomer cement disclosed in U.S. Pat. No. 4,089,830 may be used in the present invention without any difficulties.

The preferred poly(carboxylic acid) are those prepared by the homo-polymerization and co-polymerization of unsaturated aliphatic carboxylic acids and co-polymerization of unsaturated aliphatic carboxylic acids and co-polymerization of these acids with other unsaturated aliphatic monomers.

The poly(carboxylic acid) solution which is used in the preferred surgical cement according to the invention may be prepared by any of the customarily used polymerization techniques. For example, polymerization may be carried out in aqueous solution in the presence of ammonium persulphate and various chain transfer agents to give solutions containing up to about 30% of the polymer. This solution may then be concentrated, if necessary, to give a more viscous solution, or freeze-dried to give a solid particulate poly(carboxylic acid).

Various other acrylic monomers may be included in the polymerizing system to give carboxylic acid copolymers having modified properties, provided that the carboxylic acid copolymer is sufficiently soluble in water and reacts with a tricalcium phosphate powder in the required manner.

Particularly preferred poly(carboxylic acids) are (i) homopolymers of acrylic acid, or (ii) copolymers of (a) acrylic acid, preferably in an amount of 60 to 99.9% by weight, as the principal component and (b) a small amount, preferably 0.1 to 40% by weight of at least one unsaturated monomer selected from the group consisting of itaconic acid, maleic acid, fumaric acid, methacrylic acid, aconitic acid, citraconic acid, glutaconic acid, mesaconic acid, tiglic acid and a lower alkylester thereof (the alkyl group having 1 to 5 carbon atoms), and a lower alkylester of acrylic acid (C₁ to C₅ alkyl).

The surgically acceptable water-soluble poly(carboxlic acid) useful in the surgical cement of the invention has a viscosity-average molecular weight of from 2,000 to 200,000, preferably from 5,000 to 150,000, when determined by the method of Sakamoto (Chem. Abstr., 58, 13160C), 1963.

The poly(carboxylic acid) may be used in the form of powder or in the form of an aqueous solution having a concentration ranging from 10 to 60% by weight, preferably 25 to 55% by weight.

The preferred surgical cement according to the invention comprises (a) 23 to 75% by weight, most preferably 33 to 72% by weight of self-hardening α-tricalcium phosphate (component A), (b) 2 to 46% by weight, most preferably 7 to 37% by weight of a poly(carboxylic acid) (component (B)) and (c) 10 to 69% by weight, most preferably 12 to 50% by weight of water.

When the component (B) is used in the form of an aqueous solution having a concentration of 10 to 60% by weight, preferably 25 to 55% by weight, the ratio of the component (A) to the aqueous solution of the component (B) are from 0.3:1 to 3.0:1, preferably from 0.5:1 to 2.5:1.

Even if the aqueous poly(carboxylic acid) solution is used, the respective components must be adjusted so that the amount thereof falls within the aforementioned range.

The surgical cement according to the invention is preferably adjusted so that the weight ratio of the surgically acceptable water-soluble poly(carboxylic acid) to the self-hardening α-tricalcium phosphate falls within the range of from 0.4 to 0.6 and that the weight ratio of water to the self-hardening α-tricalcium phosphate falls within the range of from 0.4 to 0.7, when the surgical cement is applied, in particular, to the application in which high compressive strength is needed.

Furthermore, in the surgical cement of the invention, many other organic acids other than poly(carboxylic acid) may be included preferably in an amount up to 10% by weight, in order to control the setting speed during its application for repairing or restoring the tooth canals and so on.

In the case where the organic acid is used in the form of aqueous solution, the amount of water present in the aqueous solution of the organic acid is previously adjusted so that the total amount thereof falls within the range mentioned above.

As the organic acid which is preferably used in the surgical cement of the invention, there may be mentioned, for example, glycolic acid, glutamic acid, pantothenic acid, lactic acid, tartaric acid, citric acid, malic acid, which may be used singly or as a mixture containing two or more of them.

The surgical cement of the invention can be prepared according to the process which comprises (i) the steps of mixing (a) powder of component (A) composed of self-hardening α-tricalcium phosphate and (b) component (B) of surgically acceptable water-soluble poly(carboxylic acid) powder, kneading the mixture under the presence of desired amount of water to form fluidized or plastic product or (ii) adding desired amount of aqueous solution of the component (B) to the component (A), kneading the mixture obtained to convert it into fluid state or plastic state.

Thus, according to the invention, surgical cements can be obtained by combining α-tricalcium phosphate with poly(carboxylic acid), the cement being suitable for use as the root canal-filling material, the lining cement, the restorative agent for use in alveolar bones and having a good compatibility to living tissues.

The invention is now explained in more concretely in the light of the following non-limitative examples. In the examples, the terms "parts" and "%" are expressed as "parts by weight" and "% by weight" respectively.

REFERENCE EXAMPLE 1 Preparation of α-tricalcium phosphate

Calcium hydrogen phosphate dihydrate (CaHPO₄.2H₂ O) was calcined at 500° C. for 2 hours to form γ-calcium pyrophosphate (γ-Ca₂ P₂ O₇). The resulting pyrophosphate was further calcined at 1,200° C. for 2 hours after uniformly mixing with equimolar amount of CaCO₃, and cooled rapidly. The product thus obtained was, then, pulverized and passed through a 300 mesh sieve to adjust the particle size distribution. According to X-ray diffraction, the product is found to be α-tricalcium phosphate. This product is, hereunder, referred to as "α-TCP".

EXAMPLE 1

According to the method of JIS T-6602, α-TCP synthesized in reference example 1 was kneaded with an aqueous poly(carboxylic acid) solution and, after 24 hours, the product was subjected to compressive strength measurement. The results obtained are shown in Table I. Copolymers of acrylic acid/itaconic acid (containing 15% of itaconic acid moiety, MW=80,000 and 31,000) were used as the poly(carboxylic acid) in the example.

                  TABLE I     ______________________________________     aq. poly(carboxylic         compressive     acid)soln.                  strength     Powder  Mw*     concn. (%)  P/L** (kg/cm.sup.2)     ______________________________________     α-TCP             80,000  25          1.3   180     α-TCP             80,000  30          1.3   320     α-TCP             80,000  45          1.3   720     α-TCP             80,000  50          1.3   770     α-TCP             80,000  45          0.5   150     α-TCP             80,000  45          1.0   630     α-TCP             80,000  45          1.8   800     α-TCP             31,000  45          1.3   700     ______________________________________      *viscosity  average molecular weight (hereunder, all of the molecular      weight (MW) is expressed as viscosity  average molecular weight.)      **the weight ratio of the powder to the solution.

As evident from the results listed in Table I, α-TCP shows a sufficient compressive strength to use as the root canal-filling agent and surgical cement.

EXAMPLE 2

Previously mixing α-TCP obtained in the reference example 1 with polyacrylic acid powder and the mixture was kneaded under the presence of a desired amount of water. Then, the measurement of compressive strength on the resulting product was carried out according to the same procedure as in the example 1. The results obtained are shown in Table II. In this example, the copolymer of acrylic acid/itaconic acid (containing 15% itaconic acid moiety; MW: 80,000) was used as the poly(carboxylic acid).

                  TABLE II     ______________________________________     Amount of             Amount of       Amount of Compressive     α-TCP             poly(carboxylic acid)                             water     strength     (g)     (g)             (g)       (kg/cm.sup.2)     ______________________________________     2       0.7             1.2       530     2       1.0             1.2       580     2       1.1             1.2       550     ______________________________________

EXAMPLE 3

The procedures of the example 1 were repeated, except that the various kind of poly(carboxylic acids) were used. The results on the compressive strength measurement are listed in Table III.

                  TABLE III     ______________________________________     poly(carboxylic acid)                                       Compressive                        concn.         strength     Composition                Mw      (%)       P/L  (kg/cm.sup.2)     ______________________________________     Polyacrylic acid                 5,000  40        1.0  120     Polyacrylic acid                30,000  40        1.0  350     acrylic acid/5%                66,000  40        1.3  680     itaconic acid     copolymer     acrylic acid/30%                30,000  40        1.3  690     itaconic acid     copolymer     acrylic acid/5%                15,000  40        1.3  670     maleic acid     copolymer     acrylic acid/10%                10,000  40        1.3  670     fumaric acid     copolymer     ______________________________________

EXAMPLE 4

The setting solution obtained by adding 50% aqueous solution of an organic acid to an aqueous poly(carboxylic acid) solution was kneaded with α-TCP synthesized in the reference example 1. The compressive strength was measured on the resulting product in accordance with the procedure of the example 1. The results obtained are listed in Table IV. The aqueous poly(carboxylic acid) solution used was 45% aqueous solution of acrylic acid-itaconic acid copolymer (containing 15% itaconic acid moiety; MW: 80,000).

                  TABLE IV     ______________________________________                Amount of the        Compressive     Organic Acid                Organic acid soln.   Strength     Used.      (%)           P/L    (kg/cm.sup.2)     ______________________________________     glycolic acid                 5            1.0    650     glycolic acid                10            1.0    670     glycolic acid                20            1.0    580     citric acid                 5            1.0    680     ______________________________________

The addition of organic acid makes it possible to reduce the setting time.

EXAMPLE 5

The powder of α-TCP obtained in the reference example 1 was pressed under the pressure of 500 kg/cm² and 1,200 kg/cm², in a mold to form a tablet and then the tablet was calcined at 1,200° C. for 2 hours. The calcined tablet was finely pulverized and the powder was passed through the 300 mesh sieve. Using the powder thus produced, the procedures in the example 1 were repeated and the compressive strength was determined on the product and the results are shown in the following Table V. The aqueous poly(carboxylic acid) solutions used herein were identical to those used in the example 4.

                  TABLE V     ______________________________________     Pressure Applied      Compressive Strength     (kg/cm.sup.2)  P/L    (kg/cm.sup.2)     ______________________________________     500            1.5    990     500            2.0    1,130     1,200          1.5    960     ______________________________________

COMPARATIVE EXAMPLE 1

First of all, β-tricalcium phosphate (hereunder referred to as β-TCP) was prepared by calcining the mixture of β-calcium pyrophosphate and calcium carbonate by a conventional method, and hydroxyapatite (hereunder referred to as HAP) was also prepared by reacting calcium hydroxide with an aqueous phosphoric acid solution according to a conventional method. These were kneaded with aqueous poly(carboxylic acid) solution (the same solution as that used in the example 4) and the compressive strength was measured on the resulting products as in the example 1. The results thus obtained are shown in Table VI.

                  TABLE VI     ______________________________________                         Compressive Strength     Powder       P/L    (kg/cm.sup.2)     ______________________________________     β-TCP   1.3    no hardening     HAP          1.3    30     ______________________________________

As seen from the results listed in Table VI, β-TCP has no self-hardening property and HAP has a quite low compressive strength. Although the latter can be set, it cannot be put into practical use, because of its low strength.

COMPARATIVE EXAMPLE 2

To a mixture of α-TCP obtained in the reference example 1 and water, there was added a small amount of an inorganic acid or an organic acid and kneaded. The resulting product was subjected to the measurement of the compressive strength according to the procedure of the example 1. Table VII shows the results obtained.

                  TABLE VII     ______________________________________                                         Compressive     α-TCP           Water                Amount   Strength     (g)   (g)     Acid Used    thereof (ml)                                         (kg/cm.sup.2)     ______________________________________     3     3.5     4N HNO.sub.3 0.2      46     3     3.5     4N HCl       0.2      47     3     3.5     5% CH.sub.3 COOH                                0.5      42     3     3.5     5% HCOOH     0.5      26     ______________________________________

The results of Table VII show the fact that all the cement thus obtained has low compressive strength of less than 50 kg/cm² and, as a result, these cement cannot be put into practical use. 

What is claimed is:
 1. A surgical cement consisting essentially of:(a) a component (A) composed of self-hardening α-tricalcium phosphate powder; (b) a component (B) of surgically acceptable water-soluble poly(carboxylic acid); and (c) water.
 2. A surgical cement according to claim 1 which consists essentially of:(a) from 23 to 75% by weight of the component (A); (b) from 2 to 46% by weight of the component (B); and (c) from 10 to 69% by weight of water.
 3. A surgical cement according to claim 1, in which the component (B) is in the form of an aqueous solution containing from 10 to 60% by weight of the component (B).
 4. A surgical cement according to claim 1, which consists essentially of:(a) the component (A) and (b) an aqueous solution containing from 10 to 60% by weight of the component (B), and the weight ratio of (a) to (b) being in the range of from 0.3:1 to 3.0:1.
 5. A surgical cement according to claim 2, in which the self-hardening α-tricalcium phosphate powder is the powder obtained by compressing α-tricalcium phosphate under press, calcining the pressed tricalcium phosphate at a temperature of from 1,200° to 1,500° C. for at least one hour and then pulverizing the calcined tricalcium phosphate into fine powder.
 6. A surgical cement according to claim 1, in which the self-hardening α-tricalcium phosphate is the powder obtained by compressing amorphous tricalcium phosphate under press, calcining the pressed tricalcium phosphate at a temperature of from 1,200° to 1,500° C. for at least one hour and then finely pulverizing.
 7. A surgical cement according to claim 1, in which the poly(carboxylic acid) is a homopolymer of acrylic acid or a copolymer of (a) acrylic acid as principal monomer with (b) at least one unsaturated monomer selected from the group consisting of itaconic acid, maleic acid, fumaric acid, methacrylic acid, aconitic acid, citraconic acid, mesaconic acid, tiglic acid, and lower alkylesters thereof and lower alkylesters of acrylic acid.
 8. A surgical cement according to claim 1, in which the poly(carboxylic acid) is the homopolymer of acrylic acid or a copolymer of (a) from 60 to 99.9% by weight of acrylic acid with (b) from 0.1 to 40% by weight of at least one unsaturated monomer selected from the group consisting of itaconic acid, maleic acid, fumaric acid, methacrylic acid, aconitic acid, citraconic acid, glutaconic acid, mesaconic acid, tiglic acid and lower alkylesters thereof and lower alkylesters of acrylic acid.
 9. A surgical cement according to claim 1, in which the viscosity-average molecular weight of the poly(carboxylic acid) is in the range of from 2,000 to 200,000, as determined by the method of Sakamoto, Chemical Abstracts, 58, 13 160C,
 1963. 10. A surgical cement according to claim 1, which further contains at least one other organic acid in an amount up to 10% by weight.
 11. A surgical cement according to claim 10, in which said other organic acid is at least one member selected from the group consisting of glycolic acid, lactic acid, glutamic acid, pantothenic acid, tartaric acid, citric acid, malic acid.
 12. A process for preparing a surgical cement which consists essentially of the steps of preparing a mixture by admixing (a) a component (A) of self-hardening α-tricalcium phosphate powder and (b) a component (B) of a powdered surgically acceptable water-soluble poly(carboxylic acid) and adding a desired amount of water, or by adding aqueous solution of the component (B) to the component (A); then kneading the mixture thus obtained to convert the mixture to a fluidized state or a plastic state.
 13. A process according to claim 12, in which the amount of the component (A) is in the range of from 23 to 75% by weight, that of the component (B) is in the range of from 2 to 46% by weight and the water is used in an amount ranging from 10 to 69% by weight.
 14. A process according to claim 12, in which the weight ratio of the component (A) to the aqueous solution of the component (B) is in the range of from 0.3:1 to 3.0:1.
 15. A process according to claim 12, in which the self hardening α-tricalcium phosphate powder is obtained by compressing α-tricalcium phosphate powder under press, calcining the compressed α-tricalcium phosphate at a temperature of from 1,200° to 1,500° C. for at least one hour and finely pulverizing the calcined product.
 16. A process according to claim 12, in which the self hardening α-tricalcium phosphate is the powder obtained by compressing amorphous tricalcium phosphate powder under press, calcining the pressed tricalcium phosphate at a temperature of from 1,200° to 1,500° C. for at least one hour and then finely pulverizing the calcined product. 